Pump, Fuel Injection: Installation: Installation

WARNING: This page is about a different car, the 2016 RAM 3500 HD and 2016 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only.

Fig 1: Fuel Injection Pump & Mounting Components

Courtesy of CHRYSLER GROUP, LLC

Inspect the pump mounting surfaces at pump and mounting flange and pilot bore for nicks, cuts or damage. Inspect O-ring surfaces for nicks, cuts or damage.
Clean the injection pump mounting flange and pilot bore at gear housing. Also clean the front of injection pump.
Install a new rubber O-ring (square) (4) into machined groove at pump mounting area.
Apply clean engine oil to injection pump O-ring and pilot bore only.
The machined tapers on both injection pump shaft and injection pump gear must be absolutely dry, clean and free of any dirt or oil film. This will ensure proper gear-to-shaft tightening.
Clean the pump gear and pump shaft at machined tapers with an evaporative type cleaner such as brake cleaner.

Fig 2: Injection Pump Numbers Stamped on End of Shaft
Courtesy of CHRYSLER GROUP, LLC
FUEL INJECTION PUMP PHASING: Perform the following phasing procedure anytime the injection pump has been removed and reinstalled.
Locate the end of the fuel injection pump shaft (2). Two numbers (750 or 754 and 0) are stamped into the end of the shaft.

Fig 3: Injection Pump Phasing Mark
Courtesy of CHRYSLER GROUP, LLC

NOTE:
Fuel Injection Pump used for illustration has number 750.
Rotate the injection pump shaft until the number 5 (located in the center of number 750 or 754) is positioned at 9 o'clock (1).
Position the injection pump to mounting flange on gear housing while aligning injection pump shaft through back of injection pump gear. Be sure the number 5 is still at the 9 o'clock position (1).
Bring the engine to TDC position. Do this by rotating the crankshaft until the TDC mark on the crankshaft damper is at 12 o'clock position. It does not matter if cylinder No. 1 or No. 6 is at TDC. Again, check to be sure the number 5 is still at the 9 o'clock position (1). Rotate pump shaft accordingly.

Fig 4: Fuel Injection Pump & Mounting Components
Courtesy of CHRYSLER GROUP, LLC
After the pump is positioned flat to mounting flange, install three pump mounting nuts (6) and tighten finger tight only. Do not attempt a final tightening at this time. Do not attempt to tighten (pull) pump to gear housing using mounting nuts. Damage to pump or gear housing may occur. The pump must be positioned flat to its mounting flange before attempting to tighten three mounting nuts.
To prevent damage or cracking of components, install and tighten nuts in the following sequence:
1. Install the fuel injection pump shaft washer and nut to pump shaft. Tighten the nut finger tight only.
2. Do a preliminary (light) tightening of fuel injection pump shaft nut (1).
3. Tighten the three fuel injection pump mounting nuts to 24 N.m (18 ft. lbs.).
4. Do a final tightening of fuel injection pump shaft nut (1) to 105 N.m (77 ft. lbs.).
Fig 5: Pump Drive Gear Access Cover
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Using a 3/8" drive ratchet, install the drive gear access cover (2). Tighten the cover to 8 N.m (71 in. lbs.).

Fig 6: Fuel Rail Components
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Install the high-pressure pump-to-fuel rail fuel tube (5) and tighten union nuts to 40 N.m (30 ft. lbs.).

Fig 7: Fuel Injection Pump Components
Courtesy of CHRYSLER GROUP, LLC
Install the fuel return line. Tighten the banjo bolt (2) to 24 N.m (18 ft. lbs.).
Install the quick-connect fitting (4).
Install the clamp (5).
Connect the Fuel Control Actuator (FCA) wire harness connector (6) to rear of injection pump.

Fig 8: Intake Tube & Connecting Hose
Courtesy of CHRYSLER GROUP, LLC
Install the accessory drive belt. Refer to BELT, SERPENTINE, INSTALLATION .
Install the Charge Air Cooler (CAC) tube (3) Tighten clamps (4) to 14 N.m (124 in. lbs.).

Fig 9: CCV Oil Drain Hoses, Cylinder Head Cover & Crankcase Pressure Sensor Connector
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Install the CCV oil drains hoses (3) to the cylinder head cover.

Fig 10: Injector Harness Connectors
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Disconnect both fuel injector wire harness connectors (1).

Fig 11: Fuel Tube Silencer
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Install the fuel tube silencer (1).

Fig 12: Locating Crankcase Pressure Sensor
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Connect the crankcase pressure sensor 1 wire harness connectors (7).

Fig 13: Crankcase Pressure Sensor Wire Harness Connector & Clamp
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Connect the crankcase pressure sensor 2 wire harness connector (1).

Fig 14: EGR Bypass Valve Harness Connector & Exhaust Pressure Sensor Wire Harness Connector
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Connect the EGR cooler bypass valve wire harness connector (1).
Connect the exhaust pressure sensor wire harness connector (2).

Fig 15: Bulk Head Connector
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Position the bulk head connector (1) and install a new cable tie to secure connector.

Fig 16: Engine Cover, Bolts & Oil Dipstick
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Install the engine cover (3). Tighten bolts (1) to 10 N.m (89 in. lbs.).
Install the oil dipstick (2).
Connect both negative battery cables.
Check system for fuel or engine oil leaks.